PM/ IS 6452/ 1/ January 2019

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PRODUCT MANUAL FOR

HIGH ALUMINA CEMENT FOR STRUCTURAL USE

ACCORDING TO IS 6452: 1989

This Product Manual shall be used as reference material by all Regional/Branch Offices &

licensees to ensure coherence of practice and transparency in operation of certification under

Scheme-I of Bureau of Indian Standards (Conformity Assessment) Regulations, 2018 for

various products. The document may also be used by prospective applicants desirous of

obtaining BIS certification licence/certificate.

1. Product : IS 6452 : 1989

Title : HIGH ALUMINA CEMENT FOR STRUCTURAL USE

No. of Amendments : 5

2. Sampling Guidelines:

a) Raw material : Not applicable

b) Grouping guidelines : Not applicable

c) Sample Size : 8 Kg for Physical test and 1 kg for chemical test

3. List of Test Equipment : Please refer ANNEX – A

4. Scheme of Inspection

and Testing : Please refer ANNEX – B

5. Possible tests in a day :

(i) Alumina content (Clause 4.1)

(ii) Fineness (Clause 4.2)

(iii) Soundness (Clause 4.3)

(iv) Initial Setting time (Clause 4.4)

6. Scope of the Licence :

Licence is granted to use Standard Mark as per IS 6452 : 1989 with the following scope:

Name of the product HIGH ALUMINA CEMENT FOR STRUCTURAL USE

PM/ IS 6452/ 1/ January 2019

ANNEX A

List of Test Equipment

Major test equipment required to test as per the Indian Standard

S. No. Tests used in with Clause

Reference Test Equipment

1 Fineness

(Clause 4.2)

Blaine’s apparatus variable flow type

Stop watch with start-stop mechanism

Mercury for calibration

Balance, Standard weights

Standard Cement

Manometer liquid (di-butyl phthalate or light

mineral oil.)

Mercury of reagent grade or better, Pyknometer

Circular discs of filter paper of medium porosity

(mean pore diameter 7 µ).

Le-Chatelier’s flask

Constant temperature water bath to maintain temp.

within ± 0.1 ° C

2 Soundness by Le-chatelier

Method

(Clause 4.3)

Le-Chatelier’s water bath preferably with

thermostatic control raising temperature from

27 ± 2 0 C to boiling in 27 ± 3 minutes

Le-Chatelier’s moulds with weights and cover

glasses minimum 8 nos.

Humidity chamber with temperature & RH control

27 ± 2 0 C, RH 90 to 100 %

Steel scale 12" (304.8 mm) with LC 0.5 mm

3 Setting time

(Clause 4.4)

Vicat apparatus

Needles

Moulds

Stop Watch

Balance - 1000g ± 0.1g and Standard Weights

1mg to 500 gm

Gauging trowel of weight 210 ± 10 g

4 Compressive Strength

(Clause 4.5)

Vibration machine with timer & cube mould fitting

assembly 12000 ± 400 vibration per min.

Compressive Strength machine

Poking Rod , Petroleum Jelly

Proving ring with all accessories suitable for

calibration of CST machine

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Tachometer

Cube Moulds 70.6 × 70.6 mm, Poking rod

Gauging trowel (210 ± 10 g)

gauging plate, stainless steel(non-perforated)

Standard sand grade 1, 2 and 3 (as per IS 650)

Curing tank of appropriate size with water

circulation arrangement

Graduated glass cylinders 150 to 200 ml

Humidity chamber with temperature & RH

Control 27 ± 2° C, RH 90 to 100 %

Arrangement for maintaining temperature during

test at 18 ± 2° C

5 General equipments for Cement testing

To control humidity &

temperature in lab

1. Humidity chamber with temperature & RH

control 27 ± 2°C, RH 90 to 100 %

2. Suitable arrangement to demonstrate

maintenance of temp. of 27 ± 2 ° C & RH 65 ± 5%

constantly

For cement Sampling Mixing trays –adequate size including trays of 24

partitions for keeping hourly samples

To control the residue of cement Sieves of size (300, 212, 150, 90, 75 & 45µ)

To measure temperature

Thermometers

Lab ball mill (motorized)

To grind the clinker, slag & gypsum sample in lab

ball mill for testing

To weigh the material 1. Platform type balance

2. Electrical balance

3 Weight box with weights (1 mg - 500 g)

6 General test equipments for chemical testing Clause 4.1 of IS 6452 : 1989

Muffle Furnace with thermostatic control,

Range 0 – 1200° C

Oven with thermostatic control 0-300° C

Heater and hot plate

Distillation Assembly

Crucible: Platinum or Porcelain / silica

Filter paper (No- 1, 40, 41, 42)

Desiccators with cover & Desiccant

Water bath

pH meter/paper

Glassware - volumetric flask -0-250 ml, beaker 0-

250 ml, measuring cylinder 0-50,100,500, 1000 ml,

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burette 0-25/50 ml, conical flasks-

0-250 ml, pipette 0-5,10, 25, 50 ml

Tongs including platinum tipped tong

Wire gauge with asbestos sheet at the middle

Washing bottle

Mortar mixer- 4.75 l

Glass thermometer

All required chemicals as per IS 4032 for

determination of alumina.

The above list is indicative only and may not be treated as exhaustive.

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ANNEX B

Scheme of Inspection And Testing

1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped

(as per the requirement given in column 2 of Table 1) and staffed, where different tests given

in the specification shall be carried out in accordance with the methods given in the

specification.

1.1 The manufacturer shall prepare a calibration plan for the test equipments. The following equipments shall be calibrated at a frequency shown against each and records kept.

2. TEST RECORDS – The manufacturer shall maintain test records in various formats,

Form 1 to Form 17 for the tests carried out to establish conformity.

3. LABELLING AND MARKING – Labeling and marking shall be as given below: 3.1 STANDARD MARK - The Standard Mark, as specified by BIS, shall be printed or stenciled on each bag or drum of High Alumina Cement for Structural use or on the label applied to it, provided the material in each bag or package to which the mark thus applied conforms to the specification. The size of the Standard Mark shall be either 160 x 120 mm or 80 x 60 mm for packing in quantity of 50 kg and above. For other packing of lower quantity, a photographic reduction is permitted. 3.2 MARKING - As per the requirements of IS 6452: 1989.

3.2.1 In addition to above, following marking shall also be marked:

a) Name of original manufacturer of cement with BIS licence number in case of

repacking unit.

Sl. No. TEST EQUIPMENT FREQUENCY OF CALIBRATION

1. Blaine’s apparatus Daily with licensee’s own Standard cement sample and

monthly with standard cement samples supplied by

NCCBM.

2. Compressive

strength Testing

machine

Once in a month with Licensee’s own Proving Ring and

the Proving Ring shall be Calibrated once in two years

from a NPL/NABL Accredited Calibrating body or NPL

or NPL accredited Proving Ring manufacturer.

3. Autoclave pressure

gauge

Once in a month by licensee’s own dead weight pressure

gauge tester OR once in six months from accredited

calibrating body or NPL/NABL accredited manufacturer

of such gauges.

4. Vibration machine Once in a month by licensee’s own Tachometer. The

tachometer shall be calibrated once in a year from

NPL/NABL accredited outside agency.

5. Dead weight

pressure gauge

Tester (if available)

Once in four years from NABL accredited Tester (if

available) Lab or OEM (Original Equipment

manufacturer) having NPL/NABL accredited calibrator.

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b) Any other marking required under provisions of Legal Metrology Act, 2009 and

Legal Metrology (Packaged Commodities) Rules, 2011 framed thereunder.

3.2.2 All the information including BIS Standard Mark except Manufacturers Registered

Trade Mark shall be applied on each bag in BLACK COLOUR.

Note :

1. For each calendar year, the first week shall be counted as 7 days from 1st of January

and subsequent weeks numbered serially accordingly. The bags shall be marked as

W 0l/MM/YY…… W 51/MM/YY……. etc.

2. Label mentioned at 3.1 and 3.2 above shall be attached to the seal of the container.

The seal shall be of such a design that it shall automatically get destroyed on opening.

3. The colour of the bag and background colours should be in contrast to the colour of

the Standard Mark and the details so that the markings are conspicuous.

4. CONTROL UNIT –

4.1 For manufacturing units of High Alumina Cement for Structural use: The tests, as

indicated in Table 1 attached and at the levels of control specified therein, shall be

carried out on the whole production of the factory which is covered by this scheme and

appropriate records maintained in accordance with clause 2 above.

4.2 For packing of High Alumina Cement for Structural use at bulk cement terminal: The tests, as indicated in Table 2 attached and at the levels of control specified therein, shall

be carried out on the whole packing of High Alumina Cement for Structural use and

appropriate records maintained in accordance with clause 2 above.

4.2.1 For bulk packing units as per clause 4.2, all cement of one consignment received shall

constitute one batch.

4.2.2 Batch mixing may be permitted for packing units, which are extended packing terminals

of the same cement manufacturer (licensee) subject to packing units obtaining test certificates

from the manufacturer and keeping proper records. If the cement is received from different

units of the same manufacturer (different licensees) batch mixing of cement is not permitted.

The Batch integrity shall be ensured at all stages of packing and the packer shall maintain

appropriate controls and checks to ensure that there is no chance of mix up of different

batches. Adequate care shall be taken to avoid spoilage during handling, packing and

storage.

4.2.3 If bulk packing unit is instructed by BIS for suspension of licence due to the failure of the samples, such instruction will automatically apply to the original manufacturer of the cement, as per relevant suspension of licence guidelines. An undertaking to this effect shall be obtained from the bulk packers and the original cement manufacturer.

4.2.4 Test Certificate of each original batch of cement shall be obtained from the supplier and

test results recorded. On the basis of tests and inspection, the decision regarding conformity

or otherwise of the consignment/batch to a given requirement shall be taken. 4.3 WEIGHMENT – One filled bag from each nozzle shall be taken at random twice in each

shift of operation and weight checked in case of electronic packers with recorders. In all other

cases one filled bag from each nozzle shall be checked once in two hours. The records shall

be maintained in Form 1. The bag shall be so chosen for weighment such that bags from each

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nozzle are taken for weighment. The weighing and packing machines shall be adjusted as and

when necessary in such a way that net quantity of each bag shall be in accordance with the

tolerances given in Annex B and clause 9.2 of IS 6452 : 1989. Such adjustments for each

nozzle shall be recorded in Form 1 under remarks column.

4.3.1 For packing of High Alumina Cement for Structural use in bulk cement terminal

weighment of hourly check of mass of drums also shall be done in addition to weighment of

bags mentioned in para 4.3 above. The records of weighments shall be maintained in Forms 9

and 11.

4.4 RAW MATERIALS

4.4.1 Routine analysis of various raw materials used in the manufacture of High Alumina

Cement for Structural use shall be made at intervals of a month or whenever there is a

change in the source/mine area stratification whichever is earlier and appropriate records

of the analysis and of the Physical composition of the mixtures shall be maintained in

Form 2. This analysis is not applicable for Packing Units of High Alumina Cement for

Structural use at bulk cement terminal.

4.5. PACKING - The Cement shall be packed in bags as specified in clause 9.1 of

IS 6452 : 1989. A test certificate either from the manufacturer or from any recognized

testing laboratory shall be received along with each consignment of bags. Alternatively

the samples of bags from each consignment shall be tested by the cement manufacturer

either in his own laboratory or any other BIS recognized laboratory before they are used

for packing cement. No testing would be necessary if the bags carry BIS Certification

Mark. The bag shall be in good condition at the time of packing.

5. LEVELS OF CONTROL - The tests as indicated in column 1 of Table 1 and the levels of

control in column 3 of Table 1, shall be carried out on the whole production of the factory

which is covered by this plan and appropriate records maintained in accordance with clause 2

above.

5.1. PRODUCTION DATA - The licensee shall send to BIS a statement of quantity

produced, marked and exported by him and the value thereof at the end of each quarter of the

operative period as per the enclosed proforma and shall also submit these details to BIS at

the end of the operative year duly authenticated by a Chartered Accountant.

6. REJECTIONS – Disposal of non-conforming product shall be done in such a way so as to

ensure that there is no violation of provisions of BIS Act, 2016.

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TABLE 1

(1) (2) (3)

Test Details Test equipment

requirement

R: required (or)

S: Sub-

contracting

permitted

Levels of Control

Cl. Requirement Test Methods Clinker stage Grinding stage Packing stage Remarks

Clause Reference

4.1 Alumina

content 4.1

IS 6452

IS 4032 R

Daily composite

sample Daily composite sample

Weekly composite

sample -

4.2 Fineness 4.2 IS 6452

IS 4031 (Part 2) R -

a) Every alternate hour

from each cement mill

b) Daily composite

sample

Daily composite

sample -

4.3 Soundness 4.3 IS 6452

IS 4031 (Part 3) R - Daily composite sample

Daily composite

sample -

4.4 Setting time 4.4 IS 6452

IS 4031 (Part 5) R - Daily composite sample

Daily composite

sample -

4.5 Compressive

strength 4.5

IS 6452

IS 4031 (Part 6) R - Daily composite sample

Daily composite

sample -

Note 1: Composite sample shall be made out of hourly samples for the required period (Pl see IS 3535 Methods of sampling hydraulic cements).

If cement is manufactured using same proportion of raw materials from more than one cement mill, sample from each mill shall be tested for

fineness as per the above table. For all other parameters composite samples from all the mills shall be tested.

If cement is manufactured using different proportion of raw materials from more than one cement mill, sample from each mill shall be tested for

all requirements as per the above table.

Note 2: For manufacturing units where there is no packing silo and cement is packed directly from cement grinding, the frequency of tests specified for

cement grinding stage would apply for the various tests to be carried out on samples taken from cement mill spouts.

Note-3: Sub-contracting is permitted to a laboratory recognized by the Bureau or Government laboratories empaneled by the Bureau.

Note-4: The control unit and levels of control as decided by the by the Bureau are obligatory to which the licensee shall comply with.

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Table 2 Level of Control (Bulk Packing Unit)

Note-1: Sub-contracting is permitted to a laboratory recognized by the Bureau or Government laboratories empaneled by the Bureau.

Note-2: The control unit and levels of control as decided by the by the Bureau are obligatory to which the licensee shall comply with.

(1) (2) (3)

TEST DETAILS Test equipment

requirement

R: required (or) S:

Sub-contracting

permitted

RECOMMENDED LEVELS OF CONTROL

Clause Requirement Test Methods

Clause Reference

Number of

samples

Frequency Remarks

4.2 Fineness 4.2 IS 6452

IS 4031 (Part 2)

S One Each batch -

4.3 Soundness 4.3 IS 6452

IS 4031 (Part 3)

S One Each batch

4.4 Setting time 4.4 IS 6452

IS 4031 (Part 5)

S One Each batch

4.5 Compressive

strength 4.5

IS 6452

IS 4031 (Part 6)

S One Each batch

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Form No. 1

FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE

Date Shift Time (Hourly) No. of Bags Net mass of bags from nozzles Remark.

Form No. 2

RAW MATERIAL TESTING

Date of receipt of

material

Date of

testing

Name of Material Source of supply and consignment

No.

Details of analysis for specified requirements

Form 3

PRODUCTION DATA

(POST GRINDING DETAILS OF PRODUCTION ACCEPTED AND REJECTED FOR STANDARD MARK)

Shift Quantity Passed for Standard mark Rejected Remark

Form No. 4

CLINKER CHEMICAL COMPOSITION (DAILY COMPOSITE SAMPLE)

Date of manufacture Al2O3 Sample

Pass/Fail

Remarks

Form 5

HIGH ALUMINA CEMENT FOR STRUCTURAL USE (GRINDING) (Daily/Weekly Composite sample)

Date of grinding Al2O3 Fineness Soundness

(Le-chatelier)

Setting Time

Initial & Final

Compressive strength Sample

Pass/Fail

Action taken if

sample fails 24 h 72 h

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Form No 6

HIGH ALUMINA CEMENT FOR STRUCTURAL USE GRINDING (For Alternate Hourly Sample)

Date of grinding Time Fineness Sample

Pass/Fail

Mode of disposal or action taken if sample fails

Form No 7

HIGH ALUMINA CEMENT FOR STRUCTURAL USE PACKING STAGE (Daily/Weekly Composite Sample)

Form No 8

CALIBRATION

Sl. No

Date of

calibration

Result of Calibration (Test records indicating details of standard values and

observed values for each equipment to be kept in proforma for which various

columns be devised; as required)

Name of equipment

Action taken if equipment found

defective

Sl.No.

(If any) &

Remarks

Note : The above records are to be kept separately for each equipment.

Date of Packing Al2O3 Fineness Soundness

(Le-chatelier)

Setting Time

Initial & Final

Compressive strength Sample

Pass/Fail

Action taken if

sample fails 24 h 72 h

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RECORDS TO BE MAINTAINED AS PER TABLE-2 OF SIT (BY BULK PACKING UNIT)

Form No. 9

FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE

HOURLY CHECK OF MASS OF DRUMS

Date Time (Hourly) Condition of Drums Net quantity of cement Record of calibration of weighing scale and Date of calibration.

Form No. 10

FORMAT FOR MAINTENANCE OF RECORDS FOR THE CONDITIONS OF THE EMPTY DRUMS/BULKERS

FOR PACKING CEMENT

Date No. of empty drums/Bulkers checked No. of empty drums/Bulkers rejected Reasons/Remarks Sign of firms inspector

Form No. 11

FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE

HOURLY CHECK OF MASS OF BAGS

Date Shift Time(Hourly) No of Bags Net quantity of Bags from Nozzles Records of calibration/date of calibration of nozzles

Form No. 12

RECEIPT OF CEMENTS

Date of receipt Batch No. Supply received from Test Certificate No

Form No. 13

CEMENT DISPATCH DATA FROM PACKING

Date Quantity Passed for Standard Mark Rejected (if any) Reasons for not marking/Method of disposal

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1.

Form No 14 & 15

TEST DONE AT FACTORY (At receipt stage and at bulk packing terminal)

2.

Date Batch No. Fineness Setting Time Remarks

3.

Form No 16 & 17

HIGH ALUMINA CEMENT FOR STRUCTURAL USE (PHYSICAL TEST REPORT) (At receipt stage and at bulk packing terminal)

Date Batch No. Test Report Soundness Compressive Strength Remarks

LC 24 h 72 h